Hey guys,Here's the upfront details: Fresh carb rebuild using Randakk's kit. Floats set properly. All needle/o-ring surfaces burnished with aluminum foil. Bike fires up, idles ok after warmed up (not sync'd yet). The #2 carb is dripping fuel from the pilot, the bowl drain and, but most curiously, the bowl gasket facing the front of the bike. I measured the o-ring groove from 0.042" to 0.051" in various places around the casting. The o-ring still measures around 0.065". It should be sealing! The other three carbs are fine. Any ideas here??

The #2 carb is dripping fuel from .the pilot, the bowl drain and, but most curiously, the bowl gasket.

Well,that carb is flooding with fuel obviously.Sorry about that.You might "cure"it by tapping on the bowl with the butt end of a screwdriver.The float MAY be stuck.Otherwise it's "pull um off AGAIN " and look see.Your getting good at it.By the way,the pilot does have a very small "O"ring in there,then the flat washer,then the spring.Even a flooded bowl should not leak out of the pilot screw.In a hurry,I even put 2 floats in backwards.Leaked like a sieve.

I took them out, double-checked the float, checked the needle/o-ring/washer, put everything all back together......still leaking. A real bright light traced the fuel, not from the bowl but from the transfer passage connection to the plenum. Fuel was weeping along the carb body, around the bowl lip and made it appear as it was leaking from the bowl. By the time I got them off, the fuel trace had evaporated and not evident. So.....off come the carbs, AGAIN. Has anyone ran a longer fuel line and cranked the bike over to pressurize the carb assembly off the bike to check for leaks before?

Get the fuel supply about 4' above the carbs if you can.This will give you a little under 2psi of fuel pressure.The higher you raise the fuel the higher the pressure.The pump develops about 2.5-3 psi.Gas is a bit under 0.5 psi per foot elevation.

Yeah, I found the plenum to carb leaking at the bottom right looking at carb #2 from the left side of the bike. I got the assembly back out last night and I have a wood fixture secured to my bench so it is safely mounted and level. I'll mount my mini fuel tank about 5' up and I'll go from there. Thanks everybody.

I did this on a 78 gl1000.After finishing what you are now doing,I drained each carb into a beaker and measured the level.Surprising enough,I found that one carb had quite a noticeable amount more fuel in it.I re-adjusted the float to get them the same.It was the one cylinder that gave me an unbalanced firing and rattle.